Uneak White's Personal Brand Exploration Presentation
xdoc.pl_meb.pdf
1. Turnaround / Shutdown Management with SAP
Enterprise Asset Management
Dean Fitt
SAP AG
A collaboration of:
2. What I’ll Cover
SAP Enterprise Asset Management can be used to manage the whole lifecycle of a
Shutdown.
Integration and ease of use based on ERP components plant maintenance (PM) and
project system (PS) enabled through the use of Maintenance Event Builder (MEB).
Portfolio and Project Management (PPM) and Multi Resource Scheduling (MRS) that
support the process.
Highlight enhancements and new functionality.
Key points to Take Home
Questions
4. Why are Shutdowns so important?
Most critical periodical event during the plant life cycle.
Single most influential contributor to the total cost of maintenance.
Safety, Health, and Environment regulations must be adhered to.
Ensures future plant performance and safe-guards the investment.
Compliance with Statutory Regulations
Complex event - time of increased activity, with numerous vendors, contractors, and
heavy equipment engaged in multiple tasks in close quarters.
Involves strong interaction between Maintenance and Operations.
5. Definition
Initial Planning
Scoping
Work Lists
Plan Cost
Resource Plan
High Level Schedule
Evaluation
Demobilization
Post Mortem
Cost Reconciliation
Financial Report
Scheduling
Critical Path
Resource Leveling
Daily Schedules
Planning
EH&S Plan
Work Packages
Pre-shutdown
preparation
Align Capital Work
Cost Plan (Budget)
Typical Phases of a Shutdown
Execution
Execute Work
Packages
Time, Material
Confirmations
Manage Break-in
Work
Progress Reporting
Equipment Testing
Work Permits
H 1 H 2 H 3 H 4
Definition Planning Execution Evaluation
Timeline
Scheduling
7. Planning, Building, and
Commissioning Assets
Asset Visibility
and Performance
Operational Risk Management
Optimized Asset
Operations and Maintenance
Real Estate Lifecycle Management
Plan &
Design
Procure
& Build
Com-
mission
Operate Maintain
Decom-
mission
SAP Solution for Enterprise Asset Management
MRO
Procurement
& Inventory
Asset
Maintenance
Financial
Optimization
Reliab. Reporting
Inspection
& Calibration
Human
Resources
RFID
and
Mobile Devices
Asset
Health
Monitoring
Materials
Requirements
Planning
Project Management
Core
Financials
Design &
Specify
Procure
& Build
Decom-
mission
& Dispose
Operate &
Maintain
Enterprise
Asset
Management
SAP supports organizations to efficiently and sustainably manage the whole lifecycle of physical assets in terms of
performance, risks, and expenditures to achieve and maintain the stated business objectives.
Integrated asset management processes to collaborate across all related activities such as finance, HR, risk, and compliance – easily deployable
in modular implementable steps
Asset intelligence and a holistic view of performance, risks and expenditures throughout an asset’s lifecycle to ensure efficient utilization of assets
Continuous and proactive operational risk management to support instant decisions and minimize disruption
Leverages the SAP Business Suite
* According to PAS 55, the BSI standard for good practice in asset management
8. Definition
Portfolio and
Project
Management (PPM)
Plant Maintenance
(PM)
Project System (PS)
Maintenance Event
Builder (MEB)
Materials
Management (MM)
Maintenance Cost
Budgeting (MCB)
Evaluation
Portfolio and Project
Management (PPM)
Plant Maintenance
(PM)
Project System (PS)
Financial (FI) /
Controlling (CO)
Materials
Management (MM)
Business Intelligence
(BI)
Scheduling
Plant Maintenance
(PM)
Project System (PS)
Multi Resource
Scheduling (MRS)
Enterprise Project
Connection (EPC)
Planning
Plant Maintenance
(PM)
Project System (PS)
Maintenance Event
Builder (MEB)
Document
Management System
(DMS)
SAP Solutions Supporting Shutdown
Execution
Plant Maintenance
(PM)
Project System (PS)
Cross Application
Time Sheet (CATS)
Mobile EAM Work
Order
Materials
Management (MM)
Multi Resource
Scheduling (MRS)
9. High Level Architectural View – Shutdown Management
SAP ERP Plant Maintenance
SAP Portfolio and Project Management
SAP ERP Project System
Asset
Planning
&
Operations
Long
Term
Planning
&
Monitoring
Project
Planning
&
Execution
Portfolio Initiative (Program)
Portfolio Item (Project / Proposal)
Portfolio / Strategic Buckets
optional: Project, Phases, Tasks,
Checklist Items...
Network Activities
Project
WBS
PM Order
Notification
Technical object
Maintenance Plan
Maintenance Cost Budget
Base Planning
Object
Costing
Model
Maintenance Event
Builder
Task List
PM Order
Multi Resource
Scheduler
11. Portfolio & Project Management
(PPM)
Project System
+ PM Orders
+ Maintenance Event Builder
Multi
Resource
Scheduler
(MRS)
Job Control and
Analytics
Time
Planning
Granularity
Planning Bucket Quarterly Daily shift Hours
Monthly
Asset Details Plant/ Group Floc Floc/Equip Equip
Subsection
Resource Role level Trade
Team
Individual Individual
Team
Work details Project level Orders
operation
Operation Operation
Phases
& task
Strategic
Planning
Tactical
Planning
Execution
Planning
Detailed
Schedules
Execution
Controlling
The Planning and Scheduling Life Cycle
Definition Evaluation
Scheduling
Planning Execution
12. SAP Portfolio and Project Management
Portfolio Planning & Monitoring
Long Term Investment & Portfolio Planning
Risk Assessment, Prioritization
High Level Cost Planning
High Level Resource Planning
Capital Pre-Approval
SAP Portfolio and Project Management 5.0
Project Management & Execution
Project Scheduling
Detailed Resource Planning
Detailed Cost Planning & Approval
Scheduling & Dispatching
Regulatory Reporting
Document Management
SAP Project System (PS)
Core Processes / Activities
- Developing Work Lists and Packages
- Cost Planning
- Processing of work orders
- Update of technical assets
SAP ERP for Maintenance,
Logistics Financials, HR
13. Maintenance Event Builder (MEB) – A Workbench for Shutdowns
t
Prod. Line / Asset 1
Prod. Line / Asset 2
Prod. Line / Asset 3
Prod. Line / Asset 4
General Task Lists Standard Network / WBS
Notifications
Maintenance Event Builder
Orders
Project
Revisions
Maintenance Opportunities /
Events
Facilitates Maintenance Planning and
Scheduling
Helps eliminate redundant tasks within a
work package
Sequences maintenance tasks by assigning
them to appropriate time frames
Planning project based maintenance events
20. MEB - Review Backlog
The planner reviews all open maintenance requests that need action.
The planner can group these task based on priority, location and resources needed
21. MEB - Review Maintenance Opportunity
Planner meets with operations team to plan shutdown
Planner enters these opportunities as revisions in MEB
22. Based on the dates of the shutdown and priority, the planner assigns maintenance requirements (notification or WO) to the
event.
MEB – Creating Work Packages for the Shutdown
23. Once the work load is evaluated by operations and maintenance, the planner generates orders or assigns
generated orders to the work package
MEB - Generate Orders for a Revision
24. Maintenance Event Builder ensures that all duplicate orders that have the same task list and assigned to same technical
objects are deleted
MEB – Optimizing the Work Package
Notification
Chk1
T2
T1
ST1
ST2
ST3
ST4
ST5
SB1
ST1
ST6
ST3
Order
ST1
Order
ST3
Elimination
Revision
Order
ST3
Order
ST2
Order
ST4
Order
ST5
Order
ST1
Order
ST6
29. PM/PS - Assigning Orders to a Project Network
Orders can be assigned manually using drag and drop or automatically based on the
Reference PM/PS Element field. Transaction ADPMPS (does not require MEB)
30. •Network Scheduling:
– schedule activities of one network only
•Overall Network Scheduling
(CN24)
– schedule all connected networks/subnetworks (and PM/CS
orders) simultaneously
•Overall Network Scheduling
with Selection Options
(CN24N)
– schedule selected networks/subnetworks simultaneously
– analyze dates of subnetworks (and PM/CS orders) using the
Subnetwork Monitor
PS - Network and Overall Network Scheduling
31. PS - Project Editor
• The Project Editor is enhanced with
• Additional Data Sets for example PM/CS Order Dates
• Date Planning and Scheduling (new)
• Advanced Date Overviews and Comparison
• Usability Improvements
Display PM/CS order in
hierarchy
Activity Dates Overview
Date Planning and Scheduling
Overall Dates Overview
32. In the Gantt Chart, you can:
Display dates of project objects (Tabular area, Graphical area)
Change dates and durations (Drag time bars for WBS elements, Specify dates in tabular area)
Define user-specific settings and manage variants (for example, time bar labels)
Choose different timescales (for example, monthly)
Print and print preview Gantt chart
PS - Project Editor Gantt Chart
37. Operations and activities can
automatically be defaulted for
users in CATS
Additional data
such as remaining
work can be
entered via mouse
click.
Time Confirmation Using Cross Application Time Sheets (CATS)
38. SAP EAM Work Order Mobile Application
• Notification Management
■ Create, view, and edit notifications and related
objects (activities, items, tasks)
• Work Order Management
■ Create, view, and edit work orders
■ Display related business partners and historical data
■ Record working time and material consumption
■ List, calendar, and map view
Technical Object Management
■ View equipments and functional locations
■ Display technical object on a map
■ Display associated documents
■ Display history and characteristics
Business Partner
■ Display business partner header and contacts
■ List and map view
Inventory Management
■ Track and manage inventory
■ Material consumption booked on orders updates
inventory
Standard solution for mobilizing SAP Enterprise Asset Management
Built on industry leading Sybase Unwired Platform
Online & Offline
39. Work Permit Management (WPM)
Project with Statoil and ConocoPhillips to develop an Oil&Gas specific permit to work
solution.
Existing functionality in SAP Work Clearance Management (WCM) has been
enhanced, so that industry specific work processes for work permits can be
configured in customizing.
40. WPM - Work Preparation Create Operational Valve & Blind List
44. High Level Architectural View – Shutdown Management
SAP ERP Plant Maintenance
SAP Portfolio and Project Management
SAP ERP Project System
Asset
Planning
&
Operations
Long
Term
Planning
&
Monitoring
Project
Planning
&
Execution
Portfolio Initiative (Program)
Portfolio Item (Project / Proposal)
Portfolio / Strategic Buckets
optional: Project, Phases, Tasks,
Checklist Items...
Network Activities
Project
WBS
PM Order
Notification
Technical object
Maintenance Plan
Maintenance Cost Budget
Base Planning
Object
Costing
Model
Maintenance Event
Builder
Task List
PM Order
Multi Resource
Scheduler
45. Best Practice
Stage 1 - Developing
Planning of Effort
90% of Planned Work
Completed
Within Budget <5% Over
All Equipment inspected
Stage 2 - Maturing
Tight control of scope
Manage resource
constraints
Daily status update of
progress
95% of planned work
completed
Estimates of work based on
industry norms
Equipment available for
maintenance
Delays in equipment start-
up as a result of integrity
issues
Stage 3 – Best Practice
Portfolio management
process in place
Issues rectified early
Quality of work to ensure
on-time start-up
Materials and Resources
managed to ensure
availability at right time
Work Permit process
streamlined
Early planning
Shutdown and start-up on
time
